I'm a huge fan of Tannhauser, and have found that making player aids and such for custom units and factions isn't too difficult, however I have no idea how to make a map that will have the same feel as the official maps.

I am not concerned with drawing the maps, just their manufacture.

Does anyone have recommendations on what material and printing process I should use to go about to make something that will feel like the real deal?

Your best bet is to probably visit a local graphics printing studio (a small firm/business) and see what they can do for you. Provide them a PDF file with correct dimensions of the map and their printing equipment could fabricate something on a thick cardboard.

checkout artscow... they did the D&D game boards for me.. they great and efficient + reliable...

Thanks guys I'm going to check out artscow first, the only local small business I know of ruined a dnd map i had them laminate a few years back... at my cost... I'll keep checking around tho if artscow falls through.

Thanks again!